Global Shifts to Sustainable Aviation Fuel

Regulatory frameworks are changing across various regions to facilitate the use of sustainable aviation fuel (SAF), as the aviation sector seeks to diminish its carbon footprint. The EU’s ReFuelEU initiative serves as a key example, requiring that 70 percent of the 2050 blending mandate consist of SAF, with half of that derived from Power-to-Liquids (PtL). This policy is setting a standard for other nations, including the UK, US, and others, to implement similar regulations.

Singapore’s Pioneering SAF Initiative

Singapore’s recent decision to utilize SAF for all departing flights starting in 2026 underscores the swift incorporation of SAF into regular aviation activities. Although SAF currently makes up a small fraction of jet fuel, it possesses considerable potential for growth. There is substantial support for this movement, paving the way for a future where air travel has a minimal impact on climate change.

Current SAF Production from Vegetable Oil

Most sustainable aviation fuel is currently produced from vegetable oil, also known as ‘HVO’ fuel, using the HEFA method. This approach is preferred because the structure of vegetable oil closely resembles that of jet fuel, with long carbon and hydrogen chains and minimal impurities. Initially, the small amounts of oxygen are removed, followed by saturation, isomerization, and cutting of the hydrocarbon chains to produce jet fuel.

However, issues related to land use and scalability are driving a shift towards more varied feedstocks. Despite a reduction in demand for air travel, the need for SAF remains significant, and it is widely acknowledged that HEFA fuel cannot be scaled sufficiently due to conflicts with food production and biodiversity. Emerging alternative methods utilize various carbon-based waste materials, often referred to as second-generation biofuels or waste-based fuels.

The Rise of E-Fuels and PtL

The complexity and variability of these waste sources, coupled with the challenges of gathering and transforming them into jet fuel, present both technological and raw material challenges. Consequently, there is increasing enthusiasm for processes that utilize CO2 and green hydrogen as raw materials, known as e-fuels or Power-to-Liquids (PtL).

In utilizing CO2 along with green hydrogen generated from renewable sources, e-fuels or Power-to-Liquids (PtL) offer scalable solutions with minimal land use impact. The primary challenge for e-fuels is cost. The price of green hydrogen is crucial, depending on the cost of green electricity and the affordability of reliable low-cost electrolysers. Fortunately, prices for both are decreasing as the industry expands. Additionally, affordable pure CO2 is necessary. While biogenic or air-captured (DAC) CO2 completes a circular process, using fossil or mineral CO2, albeit non-circular, still significantly reduces emissions. The CO2 capture industry is becoming increasingly cost-effective and mature, with pure CO2 sources becoming more prevalent. Moreover, converting CO2 to fuel is simpler than often anticipated.

OXCCU’s Innovations in SAF Production

At OXCCU, we focus on a simplified, one-step process that transforms CO2 and hydrogen into SAF. We have demonstrated the ability to produce jet fuel-range hydrocarbons efficiently and selectively in a single step. Research by Imperial College London through Imperial Consultants has confirmed that OXCCU’s one-step method significantly lowers operational costs due to its high selectivity yield in the jet fuel range, reduces capital costs by 50 percent, and lessens environmental impact.

With virtually unlimited CO2 and hydrogen supplies, PtL technology holds the promise of transforming the SAF market, offering a scalable solution that overcomes the limitations of biofuels. CO2 is an abundant resource, and we are proficient in its purification, compression, and safe transportation. As electrolyser technology advances, renewables expand, and electrical grids become cleaner, green hydrogen is becoming more accessible and affordable.

Global Trends and Future Opportunities in SAF

As the demand for sustainable aviation fuel (SAF) continues to grow, the landscape is rapidly evolving, presenting vast opportunities. Initiatives like the EU’s ReFuelEU and Singapore’s recent SAF policy are accelerating SAF’s integration into standard aviation operations. Alongside the advancement of Power-to-Liquids (PtL) technology and the establishment of revenue assurance mechanisms, critical elements like locations for SAF production facilities, a robust supply chain, and access to engineering expertise are essential for widespread adoption.

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For a list of the sources used in this article, please contact the editor. 

Andrew Symes is CEO at OXCCU. OXCCU’s sustainable aviation fuel (SAF), called OXEFUEL, is created by combining captured carbon dioxide and renewably sourced green hydrogen using a novel iron-based catalyst. This innovative process results in a more cost-effective and decarbonized alternative to fossil-based Jet A fuel for commercial air travel.